Something is really wrong here, and I don't see the problem being "units" or the "configuration". My initial guess would be some part of the system is "disconnected", although CAESAR II would have warned you about that. Another potential source of error would be if you respecified the densities, and defined the values as lb/cu.ft. instead of lb/cu.in.?
If you still can't figure it out, send the job files to techsupport@coade.com and we'll take a look at it.
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Regards,
Richard Ay - Consultant